A transformer device includes: a transformer that includes a magnetic body core and a winding; a case that houses the transformer; an external terminal that is provided in the case; a relay section that is provided in the case and to which an end portion of the winding of the transformer is connected; and a conducting wire of which one end is wound around the external terminal and bonded thereto, and another end is connected to the relay section.
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1. A transformer device comprising:
a transformer that includes a magnetic body core and a winding;
a case that houses the transformer;
an external terminal that is provided in the case;
a relay section that is provided in the case and to which an end portion of the winding of the transformer is connected; and
a conducting wire of which one end is wound around the external terminal and bonded thereto, and another end is connected to the relay section,
wherein the conducting wire is formed by an extending portion of the winding of the transformer, and
the extending portion is severed at the end portion of the winding of the transformer and detached from the winding of the transformer.
2. The transformer device according to
the relay section is formed by an electrically conductive adhesive or a brazing material.
3. The transformer device according to
the relay section is formed by an electrically conductive adhesive.
4. The transformer device according to
the relay section is formed by an electrically conductive adhesive that fills a recessing section formed in the case.
5. The transformer device according to
the one end of the conducting wire is bonded to the external terminal by an electrically conductive adhesive or a brazing material.
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This application is based upon and claims the benefit of priority of the prior Japanese Patent Application No. 2013-105192, filed on May 17, 2013, the entire contents of which are incorporated herein by reference.
The embodiments discussed herein are related to a transformer device and a method for manufacturing the transformer device.
Since the past, a choke coil for a power supply circuit is known that is composed of a plate-shaped magnetic body core, a coil element that is wound around the magnetic body core, and two terminals that are formed on both end portions of a surface of the magnetic body core and respectively electrically connected to both ends of the coil element (for example, refer to Japanese Laid-open Patent Publication No. 11-243021). In the choke coil, a lead wire is connected to a terminal by high-temperature soldering, and the terminal is adhered to the surface of the magnetic body core by an electrically conductive adhesive such that the lead wire is interposed between the terminal and the magnetic body core.
When a winding of a transformer is connected to an external terminal, to increase the reliability of the connecting section, the winding of the transformer and the external terminal are sometimes bonded by a solder or the like after an end portion of the winding is wound around the external terminal. In such instances in which bonding which accompanies winding is performed, slack in the winding of the transformer is no longer present and tension is generated when the winding is wound around the external terminal.
When mounting of the transformer device is performed while the tension is still being generated, for example, during a reflow process, the winding of the transformer may become disconnected as a result of thermal contraction after thermal expansion of the winding of the transformer.
According to an aspect of the invention, a transformer device includes: a transformer that includes a magnetic body core and a winding; a case that houses the transformer; an external terminal that is provided in the case; a relay section that is provided in the case and to which an end portion of the winding of the transformer is connected; and a conducting wire of which one end is wound around the external terminal and bonded thereto, and another end is connected to the relay section.
The object and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the claims.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are not restrictive of the invention, as claimed.
Hereinafter, embodiments will be described in detail with reference to the accompanying drawings.
The transformer device 1A includes a transformer 10, a case 20, an external terminal 30, a relay section 40, and the conducting wire 60. In the example illustrated in
The transformer device 1A may be mounted on a substrate. In the example illustrated in
The transformer 10 includes a core 12 serving as a magnetic body core and a winding 14. The configuration of the transformer 10 is arbitrary. For example, the transformer 10 may be a toroidal transformer or an EI transformer. In the example illustrated in
The winding 14 includes a wound portion that is wound around the core 12, and a non-wound portion that is not wound around the core 12 and is used to connect to the external terminal 30 (with the relay section 40, described hereafter, therebetween). Hereafter, unless specifically stated, the term “winding 14” is used with no distinction between the wound portion and the non-wound portion. For example, an end portion of the winding 14 in the description hereafter corresponds with an end portion of the non-wound portion of the winding 14.
The case 20 houses the transformer 10. The case 20 may be composed of an arbitrary insulating material. The case 20 may be formed by resin molding, for example.
The external terminal 30 is provided in the case 20. As illustrated in
The external terminal 30 may have an arbitrary form. However, the external terminal 30 has a portion (such as portion 32 illustrated in
The relay section 40 is provided in the case 20. As illustrated in
The relay section 40 establishes (relays) electrical connection between the external terminal 30 and the transformer 10 by electrically connecting the end portion of the winding 14 and the end portion of the conducting wire 60 that are physically separated from each other. For example, the relay section 40 may be formed by an electrically conductive adhesive or a solder. In the relay section 40, the end portion of the winding 14 and the end portion of the conducting wire 60 may be in direct contact with each other. Alternatively, the end portion of the winding 14 and the end portion of the conducting wire 60 may be apart from each other to ensure slack that may be desired in the winding 14 and the conducting wire 60. In instances in which the end portion of the winding 14 and the end portion of the conducting wire 60 are apart from each other, the distance between the end portion of the winding 14 and the end portion of the conducting wire 60 (separation distance) may be decided based on the amounts of slack (surplus length) that may be desired in the winding 14 and the conducting wire 60. At this time, the amounts of slack that may be desired may be decided by taking into consideration respective thermal contraction states of the winding 14 and the conducting wire 60 during a mounting process of the transformer device 1A.
In the examples illustrated in
The conducting wire 60 may be composed of a copper wire, for example. One end of the conducting wire 60 is wound around the external terminal 30 and bonded thereto. The other end of the conducting wire 60 is connected to the relay section 40, as described above. As illustrated in
Conversely, in the transformer device 1A according to the present embodiment, as described above, the winding 14 of the transformer 10 is not directly wound around the external terminal 30 and bonded thereto. Rather, the winding 14 of the transformer 10 is connected to the external terminal 30 with the conducting wire 60 and the relay section 40 therebetween. Therefore, the winding 14 of the transformer 10 may be connected to the relay section 40 in a state in which slack is maintained. Consequently, tension in the winding 14 of the transformer 10 is reduced. As a result, disconnection of the winding 14 of the transformer 10 may be reduced even when the winding 14 of the transformer 10 thermally contracts (after thermal expansion) during the mounting process of the transformer device 1A (such as during the reflow process in the mounting process). In addition, the conducting wire 60 may also be connected to the relay section 40 in a state in which slack is maintained. Consequently, tension in the conducting wire 60 is reduced. Therefore, disconnection of the conducting wire 60 may be reduced even when the conducting wire 60 thermally contracts (after thermal expansion) during the mounting process of the transformer device 1A.
In addition, when the relay section 40 is formed by an electrically conductive adhesive, the relay section 40 itself has elasticity attributed to the elastic characteristics of the electrically conductive adhesive. Therefore, even when the winding 14 of the transformer 10 or the conducting wire 60 thermally contracts during the reflow process, for example, the relay section 40 elastically deforms, thereby relaxing the tension in the winding 14 of the transformer 10 and the conducting wire 60 at the relay section 40. As a result, the possibility of disconnection of the winding 14 of the transformer 10 and disconnection of the conducting wire 60 caused by thermal contraction may be further reduced.
In addition, when the relay section 40 is formed by the electrically conductive adhesive, melting of the relay section 40 as a result of heat (such as heat during the reflow process) is less likely to occur compared to when the relay section 40 is formed by a solder. Therefore, when the relay section 40 is formed by the electrically conductive adhesive, reliability of the bonding section between the winding 14 of the transformer 10 and the conducting wire 60 at the relay section 40 may be enhanced compared to when the relay section 40 is formed by a solder.
In the example illustrated in
According to the present embodiment, the conducting wire 60 may be provided separately from the winding 14 of the transformer 10. Alternatively, the conducting wire 60 may be formed from a portion of a conducting wire forming the winding 14 of the transformer 10. In other words, the conducting wire 60 may be an extending portion of the winding 14 of the transformer 10 that is severed at the end portion (end portion connected to the relay section 40) of the winding 14 of the transformer 10 and detached from the winding 14 of the transformer 10 (see
Next, an example of a method for manufacturing the transformer device 1A will be described with reference to
First, as illustrated in
Next, as illustrated in
Next, as illustrated in
Next, the winding 14 of the transformer 10 is severed with the severing point as schematically indicated by Y2 in
Next, as illustrated in
According to the method for manufacturing the transformer device 1A illustrated in
In the present example, in a manner similar to the above-described example illustrated in
Next, the conducting wire 60 is prepared. As illustrated in
Next, the other end of the conducting wire 60 and the end portion of the winding 14 of the transformer 10 are bonded to the base 22 by an electrically conductive adhesive or a solder. As a result, the relay section 40 is formed by the electrically conductive adhesive or the solder, and connection of the other end of the conducting wire 60 and the end portion of the winding 14 of the transformer 10 to the relay section 40 is actualized. In a similar manner, bonding of the end portion of the conducting wire 60 and bonding of the end portion of the winding 14 of the transformer 10 may be performed simultaneously or with a time lag.
According to the method for manufacturing the transformer device 1A illustrated in
The method for manufacturing the transformer device 1A illustrated in
In the transformer device 1B, the configuration of a relay section 40B mainly differs from that of the relay section 40 of the transformer device 1A, described above. Hereafter, configurations differing from those of the above-described transformer device 1A will mainly be described. Other configurations may be similar to those of the above-described transformer device 1A.
The relay section 40B includes a conductor layer 402, a first bonding section 404, and a second bonding section 406.
The conductor layer 402 may be formed by an electrically conductive adhesive or a solder. For example, the conductor layer 402 may be formed by the electrically conductive adhesive being applied to the base 22. In addition, for example, the conductor layer 402 may be formed by an electrically conductive ink being printed on the base 22 by a screen printing method or an inkjet printing method. Moreover, the conductor layer 402 may be formed by a metal plate that is integrated with the case 20, in a manner similar to the external terminal 30.
In a similar manner, the first bonding section 404 may be formed by an electrically conductive adhesive or a solder. The first bonding section 404 bonds the end portion of the conducting wire 60 to the conductor layer 402 on the base 22 such that the conductor wire 60 is electrically connected to the conductor layer 402.
In a similar manner, the second bonding section 406 may be formed by an electrically conductive adhesive or a solder. The second bonding section 406 bonds the end portion of the winding 14 of the transformer 10 to the conductor layer 402 on the base 22 such that the winding 14 of the transformer 10 is electrically connected to the conductor layer 402.
As described above, in the example illustrated in
In the transformer device 1B according to the present embodiment, in a manner similar to the above-described transformer device 1A, the winding 14 of the transformer 10 is not directly wound around the external terminal 30 and bonded thereto. Rather, the winding 14 of the transformer 10 is connected to the external terminal 30 with the conducting wire 60 and the relay section 40B therebetween. Therefore, the winding 14 of the transformer 10 may be connected to the relay section 40B in a state in which slack is maintained. Consequently, tension in the winding 14 of the transformer 10 is reduced. As a result, disconnection of the winding 14 of the transformer 10 may be reduced even when the winding 14 of the transformer 10 thermally contracts during the mounting process of the transformer device 1B. In addition, the conducting wire 60 may also be connected to the relay section 40B in a state in which slack is maintained. Consequently, tension in the conducting wire 60 is reduced. Therefore, disconnection of the conducting wire 60 may be reduced even when the conducting wire 60 thermally contracts during the mounting process of the transformer device 1B.
In the present example, in a manner similar to the above-described example illustrated in
Next, the winding 14 of the transformer 10 is severed with the severing point as schematically indicated by Y2 in
Next, as illustrated in
According to the method for manufacturing the transformer device 1B illustrated in
In the present example, in a manner similar to the above-described example illustrated in
Next, the conducting wire 60 is prepared. As illustrated in
Next, the other end of the conducting wire 60 is bonded to the conductor layer 402 on the base 22 by an electrically conductive adhesive or a solder. In addition, the end portion of the winding 14 of the transformer 10 is bonded to the conductor layer 402 on the base 22 by an electrically conductive adhesive or a solder. As a result, the first bonding section 404 and the second bonding section 406 of the relay section 40B are formed.
According to the method for manufacturing the transformer device 1B illustrated in
The method for manufacturing the transformer device 1B illustrated in
According to the above-described second embodiment, the conducting wire 60 and the winding 14 of the transformer 10 are bonded to the conductor layer 402 of the relay section 40B by the first bonding section 404 and the second bonding section 406. However, the conducting wire 60 and the winding 14 of the transformer 10 may be directly bonded to the conductor layer 402 of the relay section 40B. In other words, the conducting wire 60 and the winding 14 of the transformer 10 may be bonded to the base 22 by the electrically conductive adhesive that forms the conductor layer 402. In this instance, the configuration is substantially the same as that of the above-described transformer device 1A according to the first embodiment.
In the transformer device 1C, the configuration of a relay section 40C mainly differs from that of the relay section 40 of the above-described transformer device 1A. Hereafter, configurations differing from those of the above-described transformer device 1A will mainly be described. Other configurations may be similar to those of the above-described transformer device 1A.
The relay section 40C is formed within a recessing section 24 formed in the case 20. The relay section 40C may be formed by an electrically conductive adhesive or a solder. In this instance, the relay section 40C is formed by the recessing section 24 being filled with the electrically conductive adhesive or the solder. In an instance in which a plurality of relay sections 40C are set (in other words, when a similar manner of connection is actualized for each of the plurality of external terminals 30), the recessing section 24 may be formed separately for each relay sections 40C.
The third embodiment is suitable in instances in which the relay section 40C is formed by an electrically conductive adhesive that has low viscosity and may take a long period of time to harden. A reason for this is that the electrically conductive adhesive may be kept within the recessing section 24 even when the electrically conductive adhesive that has low viscosity and may take a long period of time to harden is used. In other words, leaking of the electrically conductive adhesive and the like may be suppressed.
In the transformer device 1C according to the present embodiment, in a manner similar to the above-described transformer device 1A, the winding 14 of the transformer 10 is not directly wound around the external terminal 30 and bonded thereto. Rather, the winding 14 of the transformer 10 is connected to the external terminal 30 with the conducting wire 60 and the relay section 40C therebetween. As a result, disconnection of the winding 14 of the transformer 10 and the conducting wire 60 may be reduced even when the winding 14 of the transformer 10 and the conducting wire 60 thermally contract during the mounting process of the transformer device 1C.
In the example illustrated in
The transformer device 1C may be manufactured by a method that is substantially the same as the above-described methods for manufacturing the transformer device 1A illustrated in
The embodiments are described in detail above. However, the embodiment is not limited to a specific embodiment, and various modifications and alterations may be made without departing from the scope of claims. In addition, all or a plurality of constituent elements in the above-described embodiments may be combined.
For example, in the above-described embodiments, the transformer device 1A is structured such that the rear side is open and the transformer 10 within the transformer device 1A is exposed (this similarly applies to the transformer devices 1B and 1C). However, the rear side of the transformer device 1A may be sealed by resin molding or the like. In the instance of the structure in which the rear side of the transformer device 1A is open, the relay section 40 is configured such that electrical insulation is ensured in relation to the substrate on which the transformer device 1A is mounted (this similarly applies to the relay sections 40B and 40C). For example, the position of the relay section 40 in the height direction H may be set further towards the front side than the portion of the external terminal 30 that is connected to the substrate, such that distance that may be desired between the relay section 40 and the substrate (distance in the direction perpendicular to the surface of the substrate) is ensured (this similarly applies to the relay sections 40B and 40C; the same applies hereafter). In a similar manner, in an instance in which the winding 14 of the transformer 10 and the conducting wire 60 are connected to the relay section 40 so as to have slack as described above, the relay section 40 is configured such that the winding 14 of the transformer 10 and the conducting wire 60 are not electrically connected to the substrate in an unintentional manner as a result of the slack.
In addition, in the above-described embodiments, a solder is used as an example of a brazing material. However, various types of solder may be used as the solder, regardless of the type of metal (such as tin) contained as a main ingredient. In addition, other brazing materials may be used instead of the solder. For example, the brazing material may contain gold, silver, copper, or the like. In addition, the brazing material may be hard or soft solder. Furthermore, the brazing material is not limited to a material composed of an alloy. Any type of electrically conductive material that actualizes bonding by becoming liquefied by heating and hardened by cooling (including natural cooling) may be used as the brazing material.
All examples and conditional language recited herein are intended for pedagogical purposes to aid the reader in understanding the invention and the concepts contributed by the inventor to furthering the art, and are to be construed as being without limitation to such specifically recited examples and conditions, nor does the organization of such examples in the specification relate to a showing of the superiority and inferiority of the invention. Although the embodiments of the present invention have been described in detail, it should be understood that the various changes, substitutions, and alterations could be made hereto without departing from the spirit and scope of the invention.
Itoh, Masayuki, Kurosawa, Hiroshi
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Mar 24 2014 | ITOH, MASAYUKI | Fujitsu Limited | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 032715 | /0948 | |
Apr 04 2014 | KUROSAWA, HIROSHI | Fujitsu Limited | ASSIGNMENT OF ASSIGNORS INTEREST SEE DOCUMENT FOR DETAILS | 032715 | /0948 | |
Apr 21 2014 | Fujitsu Limited | (assignment on the face of the patent) | / |
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